Drain the engine oil

Drain the engine coolant and remove the radiator.

Disconnect the intake pipes from the exhaust manifold

Remove the carburetor and fan impeller. This will protect them from accidental damage.

Removal and disassembly of the ZMZ-402 engine

Using a 14 key, we unscrew the fitting and disconnect the oil cooler hose.

Disconnect the second oil cooler hose from the timing gear cover

Remembering or writing down the location of the remaining hoses and electrical wiring, disconnect them.

Removal and disassembly of the ZMZ-402 engine

Using the “12” key, unscrew the two bolts and remove the clutch release cylinder from the clutch housing.

Remove the gearbox.

Disconnect the "mass" wire from the clutch housing cover.

Using the “17” key, we unscrew the two bolts securing the engine to the supports.

We lift the engine with a hoist or winch, carefully remove it from the engine compartment and install it on the stand.

Remove the drive and driven clutch discs and flywheel.

Removal and disassembly of the ZMZ-402 engine

With a 14 key, we unscrew six nuts and two bolts securing the clutch housing

Removal and disassembly of the ZMZ-402 engine

And remove it.

Removing and disassembling the ZMZ-402 engine

Use the “24” key to unscrew the bolt and disconnect the tube from the oil filter housing.

Removal and disassembly of the ZMZ-402 engine

Using a 13 wrench, unscrew the four nuts securing the oil filter

Removing and disassembling the ZMZ-402 engine

And remove it.

  • Remove the generator.
  • Remove the fuel pump.
  • Remove the starter.
  • Remove the coolant pump.
  • Remove the cylinder head.

Removal and disassembly of the ZMZ-402 engine

Using the “24” key, turn off and remove the oil cooler tap and oil pipe

Removal and disassembly of the ZMZ-402 engine

Using the “12” key, unscrew the fitting and remove the oil level indicator tube.

Remove the timing gear cover.

Removing and disassembling the ZMZ-402 engine

Using the “13” key, we unscrew the two nuts securing the cover of the pusher box ...

Removal and disassembly of the ZMZ-402 engine

And take it off.

Removing and disassembling the ZMZ-402 engine

We take out eight valve lifters and number them (or arrange them in order).

Removal and disassembly of the ZMZ-402 engine

With light hammer blows through the beard, knock out the key and remove the oil deflector from the crankshaft.

Removing and disassembling the ZMZ-402 engine

Removal and disassembly of the ZMZ-402 engine

Using a “12” socket or socket wrench, unscrew the two bolts securing the thrust flange through the hole in the gear.

Removal and disassembly of the ZMZ-402 engine

and take out the camshaft together with the gear.

Removal and disassembly of the ZMZ-402 engine

To prevent the cylinder liners from falling out, we fix them with a fixture and turn the block over.

Removing and disassembling the ZMZ-402 engine

With a 1Z head, we unscrew the two nuts securing the oil pump.

Removing and disassembling the ZMZ-402 engine

And remove it.

Removing and disassembling the ZMZ-402 engine

Removal and disassembly of the ZMZ-402 engine

Using an 8 hexagon wrench, unscrew the two nuts and remove the crankshaft rear seal packing holder

Removal and disassembly of the ZMZ-402 engine

With a head of 15, we unscrew the two nuts securing the connecting rod cover.

Removing and disassembling the ZMZ-402 engine

And take it off

By pressing the wooden handle of the hammer on the connecting rod, we push the piston out of the cylinder.

Removing and disassembling the ZMZ-402 engine

Remove the remaining three pistons

Removal and disassembly of the ZMZ-402 engine

With a 19 head, unscrew the two nuts and remove the main bearing cap.

Removing and disassembling the ZMZ-402 engine

Remove the remaining four covers.

Removing and disassembling the ZMZ-402 engine

Remove the crankshaft from the block.

Removal and disassembly of the ZMZ-402 engine

Remove the fixture for fixing the cylinder liners.

Risks, paint, etc. mark their position in the block so that it does not change when installing old cases